Gasket sealing arrangements

ABSTRACT

An expansion joint includes a foam strip having first and second lateral side surfaces extending axially outward to an outer edge surface, and an elongated gasket having a laterally expandable portion adhered to the outer edge surface of the foam strip, with the laterally expandable portion extending between first and second lateral end portions. The first and second lateral end portions each define at least one of a laterally outward facing bonding surface and an axially inward facing bonding surface, with the at least one bonding surface being spaced apart axially outward from the corresponding one of the first and second lateral side surfaces of the foam strip.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and all benefit of U.S. ProvisionalPatent Application Ser. No. 62/733,758, filed on Sep. 20, 2018 andentitled EXPANSION JOINT SYSTEM, and U.S. Provisional Patent ApplicationSer. No. 62/733,756, filed on Sep. 20, 2018 and entitled ADHESIONADAPTER ARRANGEMENTS FOR COMPONENTS WITH LOW SURFACE TENSION, the entiredisclosures of each of which are incorporated herein by reference.

BACKGROUND

Conventional gasket sealing arrangements for building and constructionapplications include expansion joint systems that accommodate thermaland/or seismic movements of the substrates relative to each other, forexample, through use of a compressed open celled foam materialsandwiched between the adjacent structures. Other such sealingarrangements include a variety of polymeric sheets or gaskets installedin architectural applications.

SUMMARY

According to an exemplary embodiment of the present disclosure, anexpansion joint includes a foam strip having first and second lateralside surfaces extending axially outward to an outer edge surface, and anelongated gasket having a laterally expandable portion adhered to theouter edge surface of the foam strip, with the laterally expandableportion extending between first and second lateral end portions. Thefirst and second lateral end portions each define at least one of alaterally outward facing bonding surface and an axially inward facingbonding surface, with the at least one bonding surface being spacedapart axially outward from the corresponding one of the first and secondlateral side surfaces of the foam strip.

According to another exemplary embodiment, an architectural joint systemincludes a first substrate having a lateral end surface extendingaxially outward to an outer surface, a second substrate having a lateralend surface facing the lateral end surface of the first substrate andextending axially outward to an outer surface, and an expansion jointcompressed between the first substrate and the second substrate. Theexpansion joint includes a foam strip and an elongated gasket. The foamstrip includes first and second lateral side surfaces extending axiallyoutward to an outer edge surface recessed from the outer surfaces of thefirst and second substrates, with the first lateral side surfaceengaging the lateral end surface of the first substrate and the secondlateral side surface engaging the lateral end surface of the secondsubstrate. The elongated gasket includes a laterally expandable portionadhered to the outer edge surface of the foam strip and extendingbetween first and second lateral end portions. The first lateral endportion is bonded to the first substrate at a location spaced apartaxially outward from the first lateral side surface, and the secondlateral end portion is bonded to the second substrate at a locationspaced apart axially outward from the second lateral side surface.

According to still another exemplary embodiment, a method of installingan expansion joint between first and second substrates is contemplated.In the exemplary method, a pre-compressed foam strip is installedbetween the first and second substrates, such that a first lateral sidesurface of the foam strip engages a lateral end surface of the firstsubstrate, a second lateral side surface of the foam strip engages alateral end surface of the second substrate, and an outer edge surfaceof the foam strip is recessed from outer surfaces of the first andsecond substrates. An elongated gasket is provided, having a laterallyexpandable portion extending between first and second lateral endportions. The laterally expandable portion of the elongated gasket isadhered to the outer edge surface of the foam strip. The first lateralend portion of the elongated gasket is adhered to the first substrate,and the second lateral end portion of the elongated gasket to the secondsubstrate.

According to another exemplary embodiment of the present disclosure, afield bondable polymeric seal member includes a polymeric componenthaving a first surface tension and an adhesion adapter attached to thepolymeric component and defining a bonding surface having a secondsurface tension greater than the first surface tension.

According to another exemplary embodiment, a bonded seal arrangementincludes a polymeric seal member and a substrate. The polymeric sealmember includes a polymeric component having a first surface tension andan adhesion adapter attached to the polymeric component and defining afirst bonding surface having a second surface tension greater than thefirst surface tension. The substrate defines a second bonding surfacehaving a third surface tension greater than the first surface tension,with the second bonding surface being bonded to the first bondingsurface by an adhesive layer.

According to still another exemplary embodiment, a method of making afield bondable polymeric seal member is contemplated. In one suchexemplary method, a polymeric component having a first surface tensionis provided. An adhesion adapter is attached to the polymeric component,with the adhesion adapter defining a bonding surface having a secondsurface tension greater than the first surface tension.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which are incorporated in and constitute apart of the specification, embodiments of the invention are illustrated,which, together with a general description of the invention given above,and the detailed description given below, serve to provide examples ofthe principles of this invention.

FIG. 1 is a longitudinal end schematic view of an architecturalexpansion joint system, in accordance with an exemplary embodiment ofthe present disclosure;

FIG. 1A is an axial end view of a foam strip of an expansion jointinstalled between adjacent substrates;

FIG. 2 is a longitudinal end view of an exemplary expansion jointinstalled between adjacent substrates, according to an embodiment of thepresent disclosure;

FIG. 3 is a longitudinal end view of another exemplary expansion jointinstalled between adjacent substrates, according to another embodimentof the present disclosure;

FIG. 4 is a longitudinal end view of another exemplary expansion jointinstalled between adjacent substrates, according to another embodimentof the present disclosure;

FIG. 5 is a longitudinal end view of another exemplary expansion jointinstalled between adjacent substrates, according to another embodimentof the present disclosure;

FIG. 6 is a longitudinal end view of an exemplary expansion jointgasket, according to another embodiment of the present disclosure;

FIG. 7 is a longitudinal end view of another exemplary expansion jointinstalled between adjacent substrates, according to another embodimentof the present disclosure;

FIG. 8 is a longitudinal end view of another exemplary expansion jointinstalled between adjacent substrates, according to another embodimentof the present disclosure; and

FIG. 9 is a longitudinal end view of an exemplary expansion jointgasket, according to another embodiment of the present disclosure.

FIG. 10A is a longitudinal end view of an exemplary expansion jointgasket, according to another embodiment of the present disclosure;

FIG. 10B is a longitudinal end view of an exemplary expansion jointgasket, according to another embodiment of the present disclosure;

FIG. 11 is a partial cross-sectional schematic view of an exemplary sealmember including a polymeric component and an adhesion arrangement,according to an embodiment of the present disclosure;

FIGS. 11A-11F illustrate a variety of exemplary attachment arrangementsfor a polymeric component and adhesion adapter;

FIG. 12 is a cross-sectional end view of an exemplary field bondablesealing member including a sheet gasket with an attached adhesionadapter, according to an embodiment of the present disclosure;

FIG. 13 is a cross-sectional end view of an exemplary field bondablesealing member including a sheet gasket with attached adhesion adapters,according to another embodiment of the present disclosure;

FIG. 14 is a cross-sectional end view of an exemplary field bondablesealing member including an overlay gasket with attached adhesionadapters, according to another embodiment of the present disclosure; and

FIG. 15 is a cross-sectional end view of an exemplary field bondablesealing member including an expansion gasket with attached adhesionadapters, according to another embodiment of the present disclosure.

DETAILED DESCRIPTION

As described herein, when one or more components are described as beingassembled, connected, joined, affixed, adhered, coupled, attached, orotherwise interconnected, such interconnection may be direct as betweenthe components or may be indirect such as through the use of one or moreintermediary components. Also as described herein, reference to a“member,” “component,” or “portion” shall not be limited to a singlestructural member, component, or element but can include an assembly ofcomponents, members or elements.

The Detailed Description merely describes exemplary embodiments and isnot intended to limit the scope of the claims in any way. Indeed, theinvention as claimed and described is broader than and unlimited by theexemplary embodiments, and the terms used in the claims have their fullordinary meaning.

Building and construction applications including adjacent substratesformed from rigid materials (e.g., concrete, metal, glass) typicallyemploy expansion joint systems that accommodate thermal and/or seismicmovements of the substrates relative to each other, for example, throughuse of a compressed open celled foam material sandwiched between theadjacent structures. In some conventional expansion joint systems, afoam core is coated with a cured elastomer layer or facing to providemoisture resistance or waterproofing of an exposed edge a the foam core.Additionally or alternatively, the foam core may be coated with anintumescent layer or infused with a fire retardant to provide fireresistance.

Conventional coated expansion joint systems are commonly provided asstraight sticks held under compression prior to installation, forexample, by hardboard and plastic wrapping. Due to the limited lengths(e.g., about 2 meters) of these sticks (for example, to facilitatetransportation and storage), multiple full or partial sticks are oftenrequired to complete a joint, thus requiring additional sealing betweenadjacent stick ends, for example, by application of a sealant to theadjoining ends of the elastomer facing. These additional installationsteps can result in increased installation time, and/or undesirableappearance of stick end joints.

The present disclosure contemplates systems and methods for providing anexpansion joint between adjacent structures or substrates subject torelative lateral movement over time, such as, for example, thermaland/or seismic movements of the substrates relative to each other. Suchexpansion joints may, for example, be configures to provide a waterproofseal between the substrates, and/or a fire-resistant barrier. Accordingto an exemplary aspect of the present disclosure, an expansion joint maybe formed by adhering a laterally expandable (e.g., corrugated, hinged,elastic) elongated gasket to an outer end surface of a pre-compressedfoam strip, either before or after the foam strip is installed betweenadjacent building material or architectural substrates.

FIG. 1 schematically illustrates an exemplary expansion joint 100installed between adjacent building material substrates 10, 20, such as,for example, walls, floors, roofs, or decks of a building or otherstructure, having opposed, generally parallel lateral end surfaces 11,21 extending axially outward to outer surfaces 12, 22. The expansionjoint 100 includes a foam strip 110 adhered to an elongated gasket 120configured to be laterally expandable, for example, to maintain awaterproof seal with the substrates 10, 20 along the joint 100.

The foam strip 110 includes first and second lateral side surfaces 111,112 extending axially outward from an inner edge surface 113 to an outeredge surface 114 of the foam strip 110. While the foam strip 110 isshown with an elongated gasket adhered to only the outer edge surface114, it is to be understood that the expansion joint may alternativelyinclude elongated gaskets adhered to both the outer and inner edgesurfaces, for example, to provide a watertight seal at both edges of thejoint. In one such embodiment (not shown), the expansion joint may besubstantially symmetrical about a plane bisecting the axial length ofthe expansion joint, such that the expansion joint may be installed ineither direction.

Prior to installation, the foam strip may be pre-compressed (e.g., to15%-50% of its original, non-compressed thickness, for example, intosticks or rolls of material, and maintained in a pre-compressedcondition, for example, using bindings or shrink-wrap. The foam stripmay include an open celled foam material such as, for example, one ormore of polyurethane, acrylics, silicone, polyester, or polyether foammaterials. The foam material may, but need not, be impregnated with aproperty enhancing material, such as, for example, an acrylic resin orsilicone, for example, to provide one or more enhanced properties, suchas, for example, hydrophobic properties, thermal or UV stability, fungalresistance, or fire resistance. In an exemplary embodiment, an illmod®600 pre-compressed foam seal may be utilized. At least one of the firstand second lateral side surfaces 111, 112 may be provided with anadhesive surface (e.g., a pressure sensitive adhesive, hot meltadhesive, or one or two-component chemical bonding adhesive), forexample, to facilitate positioning of the installed foam strip at leastwhile the pre-compressed foam strip is expanding into more secureengagement between the substrates 10, 20.

The elongated gasket 120 includes a laterally expandable portion 125extending between first and second lateral end portions 121, 122. Thegasket 120 may be formed from one or more of a variety of suitablematerials, including, for example, silicone, polyethylene,polypropylene, thermoplastic elastomer, ethylene propylene diene monomer(EPDM), polyvinyl chloride (PVC) or other suitable polymers orthermoplastics. The laterally expandable portion 125 may be affixed oradhered to the outer edge surface 114 of the foam strip 110, forexample, using a sealant 116 (e.g., silicone, polyurethane, otherepoxies or hybrid sealants). While a uniform coating of sealant may beapplied between the foam strip 110 and gasket 120 for continuousadhesion of the gasket to the foam strip, in other embodiments, thelaterally expandable portion 125 of the gasket 120 may be adhered to theouter edge surface 114 of the foam strip 110 at a plurality of laterallyspaced locations. This may be accomplished, for example, by applyingdiscrete beads or other patterns of sealant across the width of the foamstrip, and/or due to the shape (e.g., corrugated) of the laterallyexpandable portion 125 of the gasket 120, by which spaced apart axiallyinner portions of the laterally expandable portion make contact with theouter edge surface 114 at discrete, laterally spaced locations.

While the elongated gasket 120 may be adhered to the outer end surface114 of the foam strip 110 prior to joint installation, for storage as apre-fabricated expansion joint, in some applications, the gasket 120 maybe adhered to the foam strip 110 after the foam strip is installedbetween the building material substrates 10, 20. By adhering theelongated gasket to the foam strip after installation of the foam strip,the foam strip and gasket may be more easily transported in longersections of separate material, for example, as rolls or spools ofmaterial, thereby facilitating transportation and storage of thematerial. Additionally, by providing the foam strips and gaskets inlonger lengths, joints between sections of the expansion joint may beeliminated, making installation more efficient and less susceptible tocosmetic issues, such as lack of uniformity. FIG. 1A illustrates anaxial end view of a foam strip 110 installed between first and secondsubstrates 10, 20 with a bead of sealant 116 applied to the outer edgesurface 114 of the foam strip for subsequent adhesion of an elongated,laterally expandable gasket.

The first and second lateral end portions 121, 122 of the exemplarygasket 120 define one or more bonding surfaces 123, 124 for adhering andsealing the lateral end portions against the substrates 10, 20 using asealant (e.g., silicone, polyurethane, other epoxies or hybridsealants). To facilitate attachment of the gasket 120 after installationof the foam strip 110 between the substrates 10, 20, the bondingsurfaces may be configured to be spaced apart axially outward from thelateral side surfaces 111, 112 of the foam strip 110. As described andshown in the various embodiments herein, the bonding surfaces 123, 124may be oriented laterally outward for adhesive engagement with thelateral end surfaces 11, 21 of the first and second substrates 10, 20,and/or axially inward for adhesive engagement with the outer surfaces12, 22 of the first and second substrates. To facilitate bonding of thegasket lateral end portions 121, 122 with the substrates 10, 20, thefoam strip 110 may be installed with the outer edge surface 114 recessedfrom the outer surfaces 12, 22 of the substrates, for example, by anaxial distance approximately equal to the axial height of the laterallyexpandable portion 125 of the gasket 120.

The laterally expandable portion of an expansion joint gasket may beprovided in a variety of suitable configurations to facilitate lateralexpansion and/or contraction, including, for example, one or morecorrugations, hinges, elastic portions, or other such features. FIG. 2illustrates an exemplary expansion joint 200 installed between adjacentbuilding material substrates 10, 20, including a foam strip 210 adheredto an elongated gasket 220. The gasket 220 has a laterally expandableportion 225 including a plurality of inverted U-shaped corrugations 226,with axially inner portions 227 of the corrugations 226 adhered to theouter end surface 214 of the foam strip 210, and axially outer portions228 providing flexibility to accommodate lateral movement of thesubstrates 10, 20 with respect to each other. FIG. 3 illustrates anotherexemplary expansion joint 300 installed between adjacent buildingmaterial substrates 10, 20, including a foam strip 310 adhered to anelongated gasket 320. The gasket 320 has a laterally expandable portion325 including a plurality of V-shaped corrugations 326, with axiallyinner portions 327 of the corrugations 326 adhered to the outer endsurface 314 of the foam strip 310, and axially outer portions 328providing flexibility to accommodate lateral movement of the substrates10, 20 with respect to each other. Still other laterally expandablegasket shapes and arrangements may be utilized, including, for example,sinusoidal corrugations, rectangular corrugations, truncated V-shapedcorrugations, and U-shaped corrugations.

An expansion joint gasket may be provided in a variety of suitabledimensions, including, for example, as labeled in FIG. 6, an axialheight h of approximately ⅝ inches, or between about ¼ inch and about 1½ inches, a corrugation lateral width w of about ½ inch, or betweenabout ¼ inch and about 1 ½ inches, or a corrugation wall thickness t ofabout 0.07 inches, or between about 0.03 inches and about ⅛ inches. Thegasket may be provided in a number of different lateral widths L, forexample to accommodate expansion joints of a wide range of widths, witheach gasket width being suitable to accommodate a limited width range,due to the lateral expandability and/or compressibility of the gasket.For example, expansion joint gaskets may be provided in nominal widthsselected to accommodate expansion joints having width ranges from about75% smaller to about 100% larger than the nominal width of the expansionjoint, or from about 50% smaller to about 50% larger than the nominalwidth of the expansion joint, or any other suitable range.

As shown in FIGS. 2 and 3, the gasket corrugations 226, 326 may providegaps between the gasket 220, 320 and the foam strip 210, 310, such thatthe gasket only engages the substantially planar outer end surface 214,314 of the foam strip at the axially inner portions 227, 327. In otherembodiments, the outer end surface of the foam strip may be contoured(e.g., by mechanical cutting, laser cutting, water jet cutting, molding,extruding, additive manufacturing) to more closely mate with the axiallyinner surface of the gasket, to provide more uniform or continuousengagement between the foam strip and the gasket, for example, toprovide more uniform compression, improved adhesion to the gasket, orenhanced durability. FIG. 4 illustrates an exemplary foam strip 410having an outer end surface 414 contoured to closely mate with theaxially inner surface of a gasket having a laterally expandable portioncomprising inverted U-shaped corrugations, such as, for example, thegasket 220 of FIG. 2. FIG. 5 illustrates an exemplary foam strip 510having an outer end surface 514 contoured to closely mate with theaxially inner surface of a gasket having a laterally expandable portioncomprising V-shaped corrugations, such as, for example, the gasket 320of FIG. 3. While the more uniform or continuous mating contact betweenthe foam strip and gasket may allow for a uniform layer of sealantbetween the foam strip and the gasket, in other embodiments, as shown inFIGS. 4 and 5, sealant beads 416, 516 may be deposited in recesses orgrooves 415, 515 formed in the contoured outer end surfaces 414, 514 foradhesion of the gasket along the axially inner portions of the gasketcorrugations.

The lateral end portion bonding surfaces of an expansion joint gasketmay be provided in a variety of suitable configurations to facilitatesealing engagement with the substrates. In some embodiments, the lateralend portions of a gasket may be provided with laterally outward orientedbonding surfaces for adhesive engagement with the lateral end surfacesof the adjacent substrates. In the exemplary embodiment of FIG. 2, theouter wall portions 229 of the endmost corrugations 226 of the gasket220 define laterally outward oriented bonding surfaces 239, spaced apartaxially outward from the lateral side surfaces 211, 212 of the foamstrip 210, for adhesive engagement with the lateral end surfaces 11, 21of the substrates 10, 20. While sealant may be applied to thesubstantially axially extending surfaces that engage the substrate endsurfaces 11, 21, sealant beads may additionally or alternatively beapplied along the junctions between the curved portions endmostcorrugations 226 and the substrate end surfaces, as shown at 218. In theexemplary embodiment of FIG. 3, the endmost corrugations 326 of thegasket 320 are provided with laterally outward facing flange portions329 defining laterally outward oriented bonding surfaces 339, spacedapart axially outward from the lateral side surfaces 311, 312 of thefoam strip 310, for adhesive engagement with the lateral end surfaces11, 21 of the substrates 10, 20. While the flange portions may besubstantially planar, in other embodiments, as shown in FIG. 3, thebonding surfaces 339 may be provided with grooves 339 a or other suchrecesses for receiving and retaining an applied sealant or adhesive.FIG. 6 illustrates another exemplary embodiment of an expansion jointgasket 620 having laterally outward facing flange portions 629 defininglaterally outward oriented bonding surfaces 639 including a plurality ofgrooves or recesses 639 a, and corrugations 626 (which may, but neednot, be similar to the V-shaped corrugations 326 of the embodiment ofFIG. 3) having axially inner portions 627 with grooves or recesses 627 afor receiving and retaining an applied sealant or adhesive.

In other embodiments, the lateral end portions of an expansion jointgasket may be provided with axially inward facing bonding surfaces foradhesive engagement with the outer surfaces of the adjacent substrates.Such an arrangement may provide for an expansion joint that is moreuniform in appearance, and/or substantially flush with the substrateouter surfaces, and may, for example, limit or eliminate the need for anadhesive on the lateral side surfaces of the foam strip. FIG. 7illustrates an exemplary installed expansion joint 700 including a foamstrip 710 adhered to an elongated gasket 720 including a laterallyexpandable portion 725 (e.g., a plurality of corrugations 726, whichmay, but need not, be similar to the V-shaped corrugations 326 of theembodiment of FIG. 3), and laterally outward extending flange portions729. The flange portions 729 define axially inward facing bondingsurfaces 737, spaced apart axially outward from the lateral sidesurfaces 711, 712 of the foam strip 710, for adhesive engagement withthe lateral end surfaces 11, 21 of the substrates 10, 20. Similar to theflange portions 329, 629 of the gaskets 320, 620 of FIGS. 3 and 6, thelaterally outward extending flange portions 729 may be provided withgrooves or recesses (not shown) to facilitate retention of a bondingadhesive or sealant.

In still other embodiments, the lateral end portions of an expansionjoint gasket may be provided with both laterally outward and axiallyinward facing bonding surfaces for adhesive engagement with both thelateral end surfaces and the outer surfaces of the adjacent substrates.FIG. 8 illustrates an exemplary installed expansion joint 800 includinga foam strip 810 adhered to an elongated gasket 820 including alaterally expandable portion 825 (e.g., a plurality of corrugations 826,which may, but need not, be similar to the inverted U-shapedcorrugations 226 of the embodiment of FIG. 2), and laterally outwardextending flange portions 829. The flange portions 829 define laterallyoutward facing bonding surfaces 839 and axially inward facing bondingsurfaces 837, spaced apart axially outward from the lateral sidesurfaces 811, 812 of the foam strip 810, for adhesive engagement withthe lateral end surfaces 11, 21 of the substrates 10, 20. As shown, thebonding surfaces 839, 837 may include grooves or other such recesses 839a, 837 a to facilitate retention of a bonding adhesive or sealant.

Bonding adhesives or sealant used to seal a gasket against anarchitectural substrate often require substantial curing times to ensurean effective seal. While pressure sensitive adhesives require little orno cure time to effect a seal, gasket materials such as silicone do notallow for adequate adhesion to a pressure sensitive adhesive, forexample, due to very low surface tension of the gasket material.According to another aspect of the present disclosure, an expansionjoint gasket may include first and second lateral end portions havingattached adapter components defining adhesive bearing bonding surfaces,for bonding engagement with the architectural substrates, with theadapter components being provided in a material selected for improvedadhesion, including, for example, metals (e.g., aluminum), plastics(e.g., extruded plastics, thermoplastics, PVC), or fibrous materials(e.g., fiberglass).

FIG. 9 illustrates an exemplary embodiment of an expansion joint gasket920 having laterally outward facing flange portions 929 configured toattach to adapter components 935 defining laterally outward orientedbonding surfaces 939 carrying a pressure sensitive adhesive 918 foradhesion with the lateral end surfaces of adjacent substrates. While anysuitable attachment arrangement may be utilized, in the illustratedembodiment, ribs or other such projections 936 on the adapter components935 are received in grooves or corresponding recesses 933 in the gasketflange portions 929. The ribs 936 and grooves 933 may be keyed (e.g.,dovetail shaped) or otherwise shaped (e.g., press fit or interferencefit) for interlocking engagement to facilitate attachment. Additionally,a thin layer of sealant (e.g., silicone) may be sprayed or otherwiseapplied within the grooves 933, for improved adhesion between the gasketflanges and the adapter components, thereby providing an additionalchemical bond between the gasket flanges and adapter components, asdescribed in greater detail below. In other embodiments, the gasketflanges may be provided ribs/projections, and the adapter components maybe provided with grooves/pockets for a similar attachment.

The adhesive bonding of components, using, for example, structuraladhesives (e.g., epoxy, acrylic, urethane), non-structural adhesives(e.g., hot melt, contact adhesives), and/or pressure sensitive adhesives(e.g., peel and stick bonding tape) generally requires a componentsurface having a relatively high surface tension or surface energy forthe adhesive to adequately wet the component surface. Many polymericmaterials (e.g., plastics and elastomers), component materials oftenselected for any number of desirable properties (e.g., compressibility,elasticity, scalability, weight, chemical compatibility, low cost,durability, UV stability, Young's modulus), have relatively low surfacetensions or surface energies, making these materials especiallyresistant to adhesive bonding. Examples of materials having particularlylow surface tensions include polyethylene (about 31 mN/m), silicone(about 24 mN/m), and PTFE (about 18.5 mN/m).

According to another aspect of the present disclosure, an expandablegasket for an expansion joint may be provided with a plurality ofcorrugations (e.g., U-shaped or V-shaped corrugations, as describedherein), with axially inner portions of the corrugations including dartsor other such projections configured to be embedded or otherwisereceived in the outer end surface of a foam strip. FIG. 10A illustratesan exemplary expansion joint 1000 a installed between adjacent buildingmaterial substrates 10, 20, including a foam strip 1010 a secured to anelongated gasket 1020 a. The gasket 1020 a has a laterally expandableportion 1025 a including a plurality of V-shaped corrugations 1026 a(though other shapes may be used), with axially inner portions 1027 a ofthe corrugations 1026 a including darts or other such projections 1040 areceived in corresponding channels 1017 a in the outer edge surface 1014a of the foam strip 1010 a, and axially outer portions 1028 a providingflexibility to accommodate lateral movement of the substrates 10, 20with respect to each other. The channels 1017 a may be formed in thefoam strip 1010 a during manufacturing (e.g., as slits, slots, grooves,or raceways) or cut into the foam strip during field installation. Thegasket 1020 a may include laterally outward facing flange portions 1029a defining laterally outward oriented bonding surfaces 639 a (which mayinclude grooves/recesses as described above) for receiving and retainingan applied sealant or adhesive for direct adhesion to the substrate 10.Alternatively, a bracket 1050 a (e.g., aluminum, PVC) may be attached toa substrate 20 to define a channel 1057 a to receive a dart/projection1040 a of the gasket 1020 a. A sealant 1055 a may be applied between thegasket 1020 a and the bracket 1050 a to seal the gasket to the bracket.A similar bracket attachment arrangement may be utilized with any of theexpansion joint embodiments described herein.

As shown in FIG. 10A, the gasket corrugations 1026 a may provide gapsbetween the gasket 1020 a and the foam strip 1010 a, such that thegasket only engages the substantially planar outer end surface 1014 a ofthe foam strip at the interlocking projections 1040 a and channels 1017a. In other embodiments, the outer end surface of the foam strip may becontoured (e.g., by mechanical cutting, laser cutting, water jetcutting, molding, extruding, additive manufacturing) to more closelymate with the axially inner surface of the gasket, to provide moreuniform or continuous engagement between the foam strip and the gasket,for example, to provide more uniform compression, improved adhesion tothe gasket, or enhanced durability. FIG. 10B illustrates an exemplaryexpansion joint 1000 b with a foam strip 1010 b having an outer endsurface 1014 b contoured to closely mate with the axially inner surfaceof a gasket 1020 b having a laterally expandable portion comprisingV-shaped corrugations 1026 b, thereby eliminating the gaps between thefoam strip and the gasket. While the interlocking projections 1040 b andchannels 1017 b may provide sufficient attachment of the gasket 1020 bto the foam strip 1010 b, the more uniform or continuous mating contactbetween the foam strip and gasket may allow for application of a layerof sealant between the foam strip and the gasket to provide additionaladhesion.

Adhesives that are suitable for bonding to low surface tension polymerstypically require substantial curing times, preferably in controlledenvironments, making such adhesive bonding procedures impractical forfield installation in an outdoor environment as is the case withpolymeric sheets or gaskets installed in architectural applications. Insome applications, surface modification techniques may be used toincrease the surface tension of a material to facilitate adhesion,including, for example, abrasion, corona discharge, plasma treatment,and flame treatment. These techniques, however, may be impractical,undesirable, or impossible to perform on polymeric sheets or gaskets.

The present disclosure contemplates systems and methods for facilitatingadhesion of a low surface tension polymeric component, such as a gasket,to a substrate, such as a building component. According to an aspect ofthe present disclosure, one or more adhesion adapters may be attached tothe polymeric element to provide a bonding surface having a highersurface tension (e.g., at least about 35 mNm). This bonding surface mayfacilitate field bonding of the polymeric element to a substrate byproviding a bonding surface that is more readily wetted by an appliedadhesive. In some such embodiments, a pressure sensitive adhesive may bepre-applied to the bonding surface prior to field installation, forexample, to simplify and/or accelerate such installation.

Surface tension increasing adhesion adapters may be applied to a varietyof components, including, for example, formed rubber products, such assheet gaskets, overlay gaskets, expansion gaskets, and window tie-ins,and low friction bearings (e.g., PTFE blocks). The adhesion adapters maybe provided in a variety of different shapes and configurations,including, for example, discs, rails, pads, posts, rods, plates, andcomponents having interlocking assembly features, such as darts orslots, configured to provide one or more bonding surfaces sized andshaped for desired adhesion between the seal member and the substrate.While the bonding surfaces are shown herein as being substantiallyplanar, in other embodiments, the bonding surfaces may be contoured(e.g., concave, convex, cylindrical, conical, etc.) to suit a desiredapplication.

FIG. 11 schematically illustrates a bonded seal arrangement 1100including a seal member 1110 bonded to a substrate 1105, as contemplatedin the various exemplary embodiments of the present disclosure. The sealmember 1110 includes a low surface tension polymeric component 1120(e.g., gasket) and an adhesion adapter 1130 attached to the polymericcomponent and defining a bonding surface 1137 having a higher surfacetension to facilitate adhesion, by a sealant or adhesive 1139, to abonding surface 1107 of the substrate 1105. In one embodiment, thepolymeric component may be fabricated (e.g., extruded, molded, 3Dprinted, machined) from a material having a surface tension less thanabout 35 mNm, which may be insufficient for adequate adhesion by apreferred adhesive. Exemplary polymeric component materials include, forexample, silicone, epoxies, acrylics, urethanes, and PTFE. The adhesionadapter 1130 may be fabricated from a material having a surface tensionof at least about 35 mNm to allow for adequate adhesion by a preferredadhesive. Exemplary adhesion adapter materials include, for example,metals (e.g., aluminum), plastics (e.g., extruded plastics,thermoplastics, PVC), or fibrous materials (e.g., fiberglass). In otherexemplary embodiments, the adhesion adapter may include a bondingsurface that is treated (e.g., abrasion, corona discharge, plasmatreatment, flame treatment to have an increased surface tension (e.g.,at least about 35 mNm), relative to other surfaces of the adhesionadapter. The substrate may be a conventional building material substrate(e.g., aluminum, concrete, glass, wood, vinyl, and building composites)having a surface tension (e.g., at least about 35 mNm) sufficient to beadequately adhered by the adhesive.

The adhesive may include any of a variety of suitable adhesivematerials, including, for example, acrylics, silicones, and butyls. Insome embodiments, the adhesive may be applied in the field to either orboth of the substrate and adhesion adapter bonding surfaces 1107, 1137.In other embodiments, the adhesive 1139 may be pre-applied to thebonding surface 1137 of the adhesion adapter 1130, for example, tofacilitate adhesion of the seal member 1110 to the substrate 1105. Inone such exemplary embodiment, a pressure sensitive adhesive (e.g., adouble-sided tape, such as ACX®, manufactured by tesa SE) is pre-appliedto the bonding surface 1137. Prior to adhesion of the seal member 1110to the substrate 1105, the adhesive 1139 may be covered with a releasepaper to protect and preserve the adhesive.

The adhesion adapter 1130 may be attached to the polymeric component1120 using a variety of suitable configurations. In one embodiment, asshown in FIG. 11A, a seal member 1110 a may include an adhesion adapter1130 a attached to a polymeric component 1120 a by an adhesive 1133 a(e.g., a silicone adhesive that may be sprayed, rolled or otherwiseapplied). By providing this adhesive bond during manufacture of the sealmember 1110 a, as compared to adhesive bonds formed during fieldinstallation, a wider range of suitable curing techniques (e.g., drying,heating, radiation, etc.) may be employed. While the joined surfaces ofthe polymeric component 1120 a and adhesion adapter 1130 a are shown assubstantially planar, in other embodiments, either or both of the matingsurfaces of the polymeric component and adhesion adapter may becontoured, for example, for increased surface contact or to form shallowpockets for retaining the adhesive prior to curing. FIG. 11B illustratesa seal member 1110 b including an adhesion adapter 1130 b attached to apolymeric component 1120 b by an adhesive 1133 b, with the polymericcomponent provided with a grooved surface 1121 b to retain the adhesiveand/or to increase surface contact with the adhesive during the curingprocess.

In other embodiments, one of the polymeric component and the adhesionadapter may be provided with a recessed pocket, and the other of thepolymeric component and the adhesion adapter may be provided with acomplementary shaped projection received in the recessed pocket forinterlocking engagement of the adhesion adapter with the polymericcomponent. In one such embodiment, the projection and pocket may besized for press-fit or interference-fit engagement, with either or bothof the polymeric component and the adhesion adapter being flexibleenough to facilitate press-fit or interference-fit engagement. FIG. 11Cillustrates a seal member 1110 c including a polymeric component 1120 chaving one or more recessed pockets 1123 c and an adhesion adapter 1130c having one or more projections 1133 c received in press-fit orinterference-fit engagement with the corresponding recessed pocket(s)1123 c.

In other embodiments, the projection(s) and recessed pocket(s) may beshaped (e.g., dovetail-shaped, dart-shaped, hammerhead-shaped, etc.) forinterlocking engagement, with an enlarged distal portion of theprojection interlocking with a narrowed outer portion of the pocket. Avariety of suitable shapes and configurations may be utilized, examplesof which are illustrated in FIGS. 11D (hammerhead-shaped projection 1133d), 11E (bulbous or ball-shaped projection 1133 e), and 11F (ribbedprojection 1133 f). To receive the projection into the pocket, either orboth of the polymeric component 1120 c-f and the adhesion adapter 1130c-f may be sufficiently elastically deformable to facilitate insertion.As shown in the exemplary embodiments of FIGS. 11C and 11E, theprojections 1133 c, 1133 e may be narrower than the bonding surfaces1137 c, 1137 e. Alternatively, as shown in the exemplary embodiments ofFIGS. 11D and 11F, the narrower portions of the projections 1133 d, 1133f may be substantially the same width as bonding surfaces 1137 d, 1137f.

While the embodiments of FIGS. 11B-11F illustrate seal member attachmentarrangements including one or more projections 1133 b-f disposed on theadhesion adapter 1130 b-f and one or more recessed pockets 1123 b-fdisposed in the polymeric component 1120 b-f, in other embodiments (notshown), one or more projections (e.g., similar to the projections ofFIGS. 11C-11F) may be disposed on the polymeric member and one or morerecessed pockets may be disposed in the adhesion adapter. Additionally,while the interengaging surfaces of the projections and recessed pocketmay provide sufficient attachment of the adhesion adapters to thepolymeric component, in other embodiments, an adhesive or sealant may beapplied between the projection and the corresponding pocket (e.g.,sprayed into the pocket prior to insertion of the projection) to providean additional chemical bond between the polymeric component and theadhesion adapter.

The surface tension increasing adhesion adapter arrangements describedherein may be employed with many different types of seal members. FIG.12 illustrates an exemplary sheet gasket seal member 1210 for use, forexample, in sealing between a window frame and an adjoining buildingwall (not shown). The exemplary gasket 1210 includes a polymeric sheet1220 and a plurality of adhesion adapters 1230 attached to the sheet1220 at spaced apart locations. In the exemplary embodiment, theadhesion adapters 1230 are attached to the sheet 1220 by an adhesive orsealant 1233 (e.g., a cured silicone adhesive). The adhesion adapters1230 provide spaced apart bonding surfaces 1237 to which adhesive 1239(e.g., pressure sensitive adhesive) may be applied.

In other embodiments, the adhesion adapters may be attached to the sheetusing other arrangements (e.g., the interlocking projections andrecessed pockets of FIGS. 11B-11F). FIG. 13 illustrates an exemplarysheet gasket seal member 1310 including a polymeric (e.g., silicone)sheet 1320 and an adhesion adapter 1330 having an enlarged end (e.g.,hammerhead-shaped as shown) projection 1333 retained in interlockingengagement (and optionally also chemically bonded by a layer ofadhesive) with a complementary shaped recessed pocket 1323 in the sheet1320, which may include an enlarged portion 1324 in which the pocket1323 is disposed, to adequately receive and retain the projection 1333.The adhesion adapter 1330 defines a bonding surface 1337 carrying apressure sensitive adhesive 1339 for bonding the sheet gasket 1310 to asubstrate. While the bonding side of the sheet gasket may besubstantially planar, in the illustrated embodiment, ribs 1328 may beprovided to define gaps between the sheet gasket and the substrate, forexample, to receive additional sealant for additional bonding of thegasket 1310 to the substrate at a separate bonding surface spaced apartfrom the adhesion adapter bonding surface 1337.

FIG. 14 illustrates an exemplary overlay gasket seal member 1410 foruse, for example, to seal over a mullion or other cross bar component.The exemplary overlay gasket 1410 includes a polymeric (e.g., silicone)overlay member 1420 and first and second adhesion adapters 1430 eachhaving an enlarged end (e.g., hammerhead-shaped as shown) projection1433 retained in interlocking engagement (and optionally also chemicallybonded by a layer of adhesive) with a complementary shaped recessedpocket 1423 in enlarged side portions 1424 of the overlay member. Theadhesion adapters 1430 define bonding surfaces 1437 carrying pressuresensitive adhesive 1439 for bonding the overlay gasket 1410 to asubstrate. The side portions 1424 may be provided with fillets or othersuch recesses 1428 for receiving additional adhesive material (e.g.,beads of silicone sealant).

FIG. 15 illustrates an exemplary expansion gasket seal member 1510 foruse, for example, with an attached foam strip as an expansion jointbetween adjacent architectural substrates, which may be similar to, orincorporate features of, any of the expansion joints described above.The exemplary expansion gasket 1510 includes a polymeric (e.g.,silicone) elongated gasket member 1520 including a laterally expandable(e.g., hinged or corrugated) portion 1521 extending between first andsecond lateral end portions 1522, and first and second adhesion adapters1530 each having an enlarged end (e.g., bulbous or ball-shaped as shown)projection 1533 retained in interlocking engagement (and optionally alsochemically bonded by a layer of adhesive) with a complementary shapedrecessed pocket 1523 in the lateral end portions 1522. The adhesionadapters 1530 define bonding surfaces 1537 carrying pressure sensitiveadhesive 1539 for bonding the lateral end portions 1522 of the expansiongasket 1510 to opposed surfaces of the adjacent substrates.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, alternativesas to form, fit and function, and so on—may be described herein, suchdescriptions are not intended to be a complete or exhaustive list ofavailable alternative embodiments, whether presently known or laterdeveloped. Those skilled in the art may readily adopt one or more of theinventive aspects, concepts or features into additional embodiments anduses within the scope of the present inventions even if such embodimentsare not expressly disclosed herein. Additionally, even though somefeatures, concepts or aspects of the inventions may be described hereinas being a preferred or desired arrangement or method, such descriptionis not intended to suggest that such feature is required or necessaryunless expressly so stated. Still further, exemplary or representativevalues and ranges may be included to assist in understanding the presentdisclosure, however, such values and ranges are not to be construed in alimiting sense and are intended to be critical values or ranges only ifso expressly stated. Parameters identified as “approximate” or “about” aspecified value are intended to include both the specified value andvalues within 10% of the specified value, unless expressly statedotherwise. Further, it is to be understood that the drawingsaccompanying the present application may, but need not, be to scale, andtherefore may be understood as teaching various ratios and proportionsevident in the drawings. Moreover, while various aspects, features andconcepts may be expressly identified herein as being inventive orforming part of an invention, such identification is not intended to beexclusive, but rather there may be inventive aspects, concepts andfeatures that are fully described herein without being expresslyidentified as such or as part of a specific invention, the inventionsinstead being set forth in the appended claims. Descriptions ofexemplary methods or processes are not limited to inclusion of all stepsas being required in all cases, nor is the order that the steps arepresented to be construed as required or necessary unless expressly sostated.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicant torestrict or in any way limit the scope of the invention to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. For example, the specific locations of the componentconnections and interplacements can be modified. Therefore, theinvention, in its broader aspects, is not limited to the specificdetails, the representative apparatus, and illustrative examples shownand described. Accordingly, departures can be made from such detailswithout departing from the spirit or scope of the applicant's generalinventive concept.

1.-92. (canceled)
 93. An expansion joint comprising: a foam strip havingfirst and second lateral side surfaces extending axially outward to anouter edge surface; and an elongated gasket having a laterallyexpandable portion adhered to the outer edge surface of the foam strip,the laterally expandable portion extending between first and secondlateral end portions each defining at least one of a laterally outwardfacing bonding surface and an axially inward facing bonding surface, theat least one bonding surface being spaced apart axially outward from thecorresponding one of the first and second lateral side surfaces of thefoam strip.
 94. The expansion joint of claim 93, wherein the outer edgesurface of the foam strip is a substantially planar surface.
 95. Theexpansion joint of claim 93, wherein the outer edge surface of the foamstrip is contoured to be closely received in a plurality of corrugationsof the laterally expandable portion of the elongated gasket.
 96. Theexpansion joint of claim 93, wherein the laterally expandable portion ofthe elongated gasket includes a plurality of V-shaped corrugations. 97.The expansion joint of claim 93, wherein the laterally expandableportion of the elongated gasket includes a plurality of invertedU-shaped corrugations.
 98. The expansion joint of claim 93, wherein thefoam strip comprises at least one of polyurethane, polyethylene,acrylics, silicone, polyester, and polyether foam materials.
 99. Theexpansion joint of claim 93, wherein at least one of the first andsecond lateral side surfaces of the foam strip comprises a pressuresensitive adhesive.
 100. The expansion joint of claim 93, wherein the atleast one bonding surface of the first and second lateral end portionsdefines a recessed portion for receiving a sealant.
 101. The expansionjoint of claim 100, wherein the recessed portion includes a plurality ofgrooves.
 102. The expansion joint of claim 93, wherein the first andsecond lateral end portions of the elongated gasket include laterallyoutward extending flange portions defining axially inward facing bondingsurfaces.
 103. The expansion joint of claim 93, wherein the elongatedgasket has an axial height of between about ¼ inch and about 1 ½ inches.104. The expansion joint of claim 93, wherein the elongated gasket has anominal lateral width selected to accommodate expansion joints havingwidth ranges from about 75% smaller to about 100% larger than thenominal width of the expansion joint.
 105. The expansion joint of claim93, wherein the laterally expandable portion has a wall thickness ofbetween about 0.03 inches and about ⅛ inches.
 106. The expansion jointof claim 93, wherein the laterally expandable portion includes aplurality of corrugations each having a lateral width of between about ¼inch and about 1 1/2 inches.
 107. The expansion joint of claim 93,wherein the laterally expandable portion is adhered to the outer edgesurface of the foam strip at a plurality of laterally spaced locations.108. The expansion joint of claim 93, wherein the at least one bondingsurface of the corresponding ones of the first and second lateral endportions includes a pressure sensitive adhesive.
 109. The expansionjoint of claim 93, wherein the laterally expandable portion includesdownward projections received in corresponding channels in the outeredge surface of the foam strip.
 110. An architectural joint systemcomprising: a first substrate having a lateral end surface extendingaxially outward to an outer surface; a second substrate having a lateralend surface facing the lateral end surface of the first substrate andextending axially outward to an outer surface; and an expansion jointcompressed between the first substrate and the second substrate, theexpansion joint comprising: a foam strip having first and second lateralside surfaces extending axially outward to an outer edge surfacerecessed from the outer surfaces of the first and second substrates, thefirst lateral side surface engaging the lateral end surface of the firstsubstrate and the second lateral side surface engaging the lateral endsurface of the second substrate; and an elongated gasket having alaterally expandable portion adhered to the outer edge surface of thefoam strip and extending between first and second lateral end portions,the first lateral end portion being bonded to the first substrate at alocation spaced apart axially outward from the first lateral sidesurface and the second lateral end portion being bonded to the secondsubstrate at a location spaced apart axially outward from the secondlateral side surface.
 111. The system of claim 110, wherein the firstand second lateral end portions of the elongated gasket are bonded tothe lateral surfaces of the first and second substrates.
 112. A methodof installing an expansion joint between first and second substrateshaving opposed lateral end surfaces extending axially outward to outersurfaces, the method comprising: installing a pre-compressed foam stripbetween the first and second substrates, such that a first lateral sidesurface of the foam strip engages the lateral end surface of the firstsubstrate, a second lateral side surface of the foam strip engages thelateral end surface of the second substrate, and an outer edge surfaceof the foam strip is recessed from the outer surfaces of the first andsecond substrates; providing an elongated gasket having a laterallyexpandable portion extending between first and second lateral endportions; adhering the laterally expandable portion of the elongatedgasket to the outer edge surface of the foam strip; adhering the firstlateral end portion of the elongated gasket to the first substrate; andadhering the second lateral end portion of the elongated gasket to thesecond substrate.